Scaffolding around a dome roof tank
Build Division / Structural Concrete

Structural
Concrete.

Reinforced and post-tensioned concrete, formwork engineering and the finishes that decide whether a structure lasts thirty years or thirteen.

The Discipline

Concrete Is
The Product.

Most of what Unicon builds is concrete, and most of that concrete has to be watertight, load-bearing or both. Over thirty-five years the company has specialised in the harder end of that: circular post-tensioned walls, dome roofs, suspended decks and liquid-retaining structures where the specification allows almost no crack width.

Structural concrete is not a separate division so much as the discipline underneath the water, civils and building teams. The same supervisors, formwork systems and testing regime move between a reservoir, a bridge deck and a suspended slab in a shopping centre.

Scope Of Works

The Concrete Work We Self-Perform.

Concrete is where we keep the work in-house rather than subcontract it, because it is where the risk sits.

Post-Tensioned Structures

  • Circular post-tensioned reservoir walls, vertical and circumferential
  • Tendon installation, ducting, anchorages and stressing to recorded elongation
  • Grouting, anchorage protection and stressing records for handover
  • Post-tensioned suspended slabs and transfer structures
  • Coordination with specialist PT designers and suppliers
  • Load testing and monitoring where specified

Reinforced Concrete Frames

  • Bases, pile caps, ground beams and raft foundations
  • Columns, beams, shear walls and cores
  • Suspended slabs: flat, ribbed, coffered and beam-and-slab
  • Stairs, lift shafts, ramps and plant plinths
  • Retaining walls, basement structures and tanking
  • Precast elements, erection and structural connections

Formwork & Falsework

  • Purpose-made circular and curved wall formwork
  • Panel and climbing systems for tall lifts
  • Soffit and table forms for suspended slabs
  • Dome and shell formwork, including plate-clad metal domes
  • Falsework design, propping and back-propping to load
  • Off-shutter and fair-face finishes to specified tolerance

Mix Design & Testing

  • Mix designs for durability, watertightness and workability, not just strength
  • Trial mixes and trial panels ahead of critical pours
  • Slump, temperature and cube testing on every structural pour
  • Hot and cold weather concreting procedures
  • Curing regimes matched to element and exposure
  • Independent laboratory testing and result trending

Reinforcement & Steel

  • Cut-and-bend rebar scheduling, fixing and cover control
  • Mesh, couplers, starter bars and lap arrangements
  • Structural steel frames, portal frames and roof structures
  • Holding-down bolts, base plates and grouting
  • Steel-plate dome and cladding installation
  • Corrosion protection and galvanising through approved suppliers

Durability & Repair

  • Waterstops, construction joints and movement joint detailing
  • Joint sealants, bearings and expansion provision
  • Crack injection, epoxy repair and concrete rehabilitation
  • Potable-grade internal linings and protective coatings
  • Cathodic and surface protection where specified
  • Structural investigation and remedial method statements

Track Record

What We Have Actually Built.

Straight from our project database, not a brochure. Contract values are shown as bands.

14

Projects delivered

2003–2016

Years active

8

Client organisations

24 months

Longest contract

Year Project Client Value
2016 Thabazimbi 10ML Reservoir with Dome Roof Anglo American R5–20M
2015 Ntwasahlobo Bridge P-127 KZN Department Of Transport R5–20M
2014 Mkomazi River Bridge KZN Department Of Transport R5–20M
2014 Mason 10Meg Reservoir & Pipeline Msunduzi Local Municipality R20–50M
2014 Makhathini Drainage Canal near Jozini Ezemvelo KZN Wildlife R20–50M
2013 Mlazi Pedestrian Bridge KZN Department Of Transport Under R5M
2013 Inanda Road Services Relocation KZN Department Of Transport Under R5M
2013 Inanda Road Bridge Widening KZN Department Of Transport R5–20M
2013 Nzinga River Bridge P-127 KZN Department Of Transport R5–20M
2009 uMzimkhulu storage dam - NPS UGU District Municipality Under R5M
2009 SAFAL STEEL Cato Ridge Safal Steel R5–20M
2008 Nestle Coffee Factory – Upgrade & Additions Nestle SA (Pty) Ltd R20–50M

Showing the twelve most recent of 14. The full database is searchable here.

Who We Build For

KZN Department Of Transport ×7Anglo American ×1Msunduzi Local Municipality ×1Ezemvelo KZN Wildlife ×1UGU District Municipality ×1Safal Steel ×1Nestle SA (Pty) Ltd ×1Bernard Keal ×1
Reservoir dome reinforcement ahead of a concrete pour

Method

Why The Pour Is Planned Before It Is Poured.

01

Method statement and pour plan

Sequence, joint positions, placement rate, plant, standby plant and labour are agreed with the engineer in writing before the pour is booked.

02

Formwork and reinforcement check

Formwork alignment, tie positions, cover, joint preparation and waterstops are inspected and signed. This is the last moment anything can be fixed cheaply.

03

Placement

Continuous placement at the agreed rate with correct vibration, controlled lift heights and monitored temperature. A pour that stops halfway makes a joint nobody designed.

04

Curing

Curing starts immediately and runs for the specified period. On water-retaining work this is the single most common cause of defects elsewhere, and we treat it accordingly.

05

Strip, inspect, record

Strike to the agreed strength, inspect the finish, record the cube results and close out the pour in the quality file.

Capacity

Plant & Teams.

We self-perform the work that carries the risk and subcontract the rest to an approved vendor list. What follows is the plant and capability this discipline draws on.

  • Circular, curved, panel and climbing formwork systems
  • Concrete pumps, placing booms, skips and poker vibrators
  • Mobile and tower cranes, telehandlers and material hoists
  • Rebar fixing, cutting and bending equipment
  • Curing equipment, covers and temperature monitoring
  • Survey and setting-out instruments for tolerance control
Supply to our sites

Contracting

How We Are Appointed.

Counts below are across the whole portfolio and come from the same database as the project record above.

Appointment Type

  • Full Contract75
  • Construction Management12
  • Turnkey4
  • Architechural Design1

Contract Form

  • GCC62
  • JBCC Series 6.215
  • JBCC Series 54
  • JBCC Series 33

CIDB 7CE and 7GB. B-BBEE Level 2 contributor. Work is measured and constructed to the SANS 1200 and SANS 2001 series, with building work to SANS 10400.

Alongside This

Related Capability.

Need Concrete Done Properly?

If the structure has to hold water, carry load or be built to a tolerance, talk to us before the method is fixed.